E x p o s u r e M o n i t o r i n g

Model 8520 DUSTTRAK Aerosol Monitor

TRAKPRO Data Analysis Software enclosed

Operation and Service Manual

1980198, Revision S June 2010

E x p o s u r e M o n i t o r i n g

Model 8520 DUSTTRAK Aerosol Monitor

Operation and Service Manual

1980198, Revision S June 2010

SHIP/MAIL TO: TSI Incorporated 500 Cardigan Road Shoreview, MN 55126-3996 USA U.S. Technical Support: (800) 874-2811/(651) 490-2811 Fax: (651) 490-3824

E-mail address: answers@tsi.com

Website: http://www.tsi.com

INTERNATIONAL

Technical Support: (001 651) 490-2811

Fax: (001 651) 490-3824

Copyright TSI Incorporated / 19942010 / All rights reserved.

Address TSI Incorporated / 500 Cardigan Road / Shoreview, MN 55126 / USA

Fax No. (651) 490-3824 Limitation of Warranty and Liability (effective July 2000) Seller warrants the goods sold hereunder, under normal use and service as described in the operator's manual, shall be free from defects in workmanship and material for twenty-four (24) months, or the length of time specified in the operator's manual, from the date of shipment to the customer. This warranty period is inclusive of any statutory warranty. This limited warranty is subject to the following exclusions: a. Hot-wire or hot-film sensors used with research anemometers, and certain other components

when indicated in specifications, are warranted for 90 days from the date of shipment. b. Parts repaired or replaced as a result of repair services are warranted to be free from defects

in workmanship and material, under normal use, for 90 days from the date of shipment. c. Seller does not provide any warranty on finished goods manufactured by others or on any

fuses, batteries or other consumable materials. Only the original manufacturer's warranty applies.

d. Unless specifically authorized in a separate writing by Seller, Seller makes no warranty with respect to, and shall have no liability in connection with, goods which are incorporated into other products or equipment, or which are modified by any person other than Seller.

The foregoing is IN LIEU OF all other warranties and is subject to the LIMITATIONS stated herein. NO OTHER EXPRESS OR IMPLIED WARRANTY OF FITNESS FOR PARTICULAR PURPOSE OR MERCHANTABILITY IS MADE. TO THE EXTENT PERMITTED BY LAW, THE EXCLUSIVE REMEDY OF THE USER OR BUYER, AND THE LIMIT OF SELLER'S LIABILITY FOR ANY AND ALL LOSSES, INJURIES, OR DAMAGES CONCERNING THE GOODS (INCLUDING CLAIMS BASED ON CONTRACT, NEGLIGENCE, TORT, STRICT LIABILITY OR OTHERWISE) SHALL BE THE RETURN OF GOODS TO SELLER AND THE REFUND OF THE PURCHASE PRICE, OR, AT THE OPTION OF SELLER, THE REPAIR OR REPLACEMENT OF THE GOODS. IN NO EVENT SHALL SELLER BE LIABLE FOR ANY SPECIAL, CONSEQUENTIAL OR INCIDENTAL DAMAGES. SELLER SHALL NOT BE RESPONSIBLE FOR INSTALLATION, DISMANTLING OR REINSTALLATION COSTS OR CHARGES. No Action, regardless of form, may be brought against Seller more than 12 months after a cause of action has accrued. The goods returned under warranty to Seller's factory shall be at Buyer's risk of loss, and will be returned, if at all, at Seller's risk of loss. Buyer and all users are deemed to have accepted this LIMITATION OF WARRANTY AND LIABILITY, which contains the complete and exclusive limited warranty of Seller. This LIMITATION OF WARRANTY AND LIABILITY may not be amended, modified or its terms waived, except by writing signed by an Officer of Seller. Service Policy Knowing that inoperative or defective instruments are as detrimental to TSI as they are to our customers, our service policy is designed to give prompt attention to any problems. If any malfunction is discovered, please contact your nearest sales office or representative, or call TSI at (800) 874-2811 (USA) or (001 651) 490-2811 (International).

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CONTENTS

SAFETY INFORMATION .................................................................... V 1 UNPACKING AND PARTS IDENTIFICATION ............................ 1

Unpacking the DUSTTRAK Aerosol Monitor .................................... 1 Parts Identification for the DUSTTRAK Aerosol Monitor .................. 2

2 SETTING-UP ................................................................................. 5 Supplying Power to the DUSTTRAK Aerosol Monitor ..................... 5

Installing the Batteries............................................................. 5 Using the AC Adapter ............................................................. 5

Instrument Setup ........................................................................... 6 Setting-up TRAKPRO Data Analysis Software ......................... 6 Connecting the DUSTTRAK Aerosol Monitor to the

Computer ............................................................................. 6 Set-Up the Communications Port ........................................... 6 Setting the Real-Time Clock ................................................... 7 Programming the Date/Time Using TRAKPRO Software ......... 8 Manually Setting the Real-Time Clock ................................... 8

Connecting the Optional Portable Printer ...................................... 8 Connecting/Wiring the Analog/Alarm Output Connector ............... 9

3 OPERATION ............................................................................... 11 Overview ...................................................................................... 11 DUSTTRAK Aerosol Monitor Keypad Functions ............................ 11 ON/OFF Key ................................................................................ 11 SAMPLE Key ............................................................................... 12 TIME CONSTANT Key ................................................................ 12 Programming the Available Time Constants ............................... 13 STATISTICS Key ......................................................................... 13 PRINT Key ................................................................................... 14 SAMPLING MODE Key ............................................................... 14

Survey Mode ......................................................................... 14 LOG Modes ........................................................................... 15

CLEAR MEMORY Key ................................................................ 15 LOGGING INTERVAL Key .......................................................... 15 Programming the Logging Intervals using TRAKPRO Software ... 16 and Keys ............................................................................. 17 CALIBRATE Key ......................................................................... 17 Display/Keypad Lockout Switch .................................................. 17 Remote Sampling ........................................................................ 17 Respirable Mass Sampling with the Cyclone .............................. 18 Using the Cyclone ....................................................................... 18 Using the 1.0 or 2.5 m Inlet Conditioners .................................. 19 Using the 10 m Nozzle .............................................................. 20 Analog Output .............................................................................. 21

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Alarm Output ................................................................................ 22 Alarm Output Specifications .................................................. 23 Programming the Alarm Setpoint .......................................... 24

Upgrading the DUSTTRAK Aerosol Monitor to Add Analog and Alarm Functions ....................................................................... 24

Identifying an Instrument with Analog/Alarm Functions ........ 24 Identifying an Instrument that may be Upgraded to Add

Analog/Alarm Functions ..................................................... 25 Identifying an Instrument That May Not Be Upgraded .......... 25

Programming Advanced Modes: LOG 2 and LOG 3 ................... 26 Sample Protocol for LOG 2 and LOG 3 Modes ........................... 29 Things You Should Know About Taking Pre-Programmed

Samples .................................................................................... 30 Memory Considerations ............................................................... 31 Custom Calibrations .................................................................... 31 Determining the Calibration Factor for a Specific Aerosol .......... 32 Setting Custom Calibration Factor from Keypad ......................... 33 Setting Custom Calibration Factors using TRAKPRO Software .... 34 Converting Stored Data to Calibrated Data ................................. 35

4 MAINTENANCE .......................................................................... 37 Maintenance Schedule ................................................................ 37 Zero Checking/Re-Zeroing .......................................................... 38 Cleaning the 1.0 m and 2.5 m Inlet Conditioners .................... 39 Cleaning the 10 m Inlet and Sample Tube ................................ 40 Replacing the Internal Filters ....................................................... 41 Setting the Flow Rate .................................................................. 43 Cleaning the Cyclone .................................................................. 44 Storage Precautions .................................................................... 44

5 TROUBLESHOOTING ................................................................ 45 A SPECIFICATIONS....................................................................... 49 B MODEL 8520-1 DUSTTRAK ENVIRONMENTAL ENCLOSURE

OPERATION AND MAINTENANCE MANUAL .......................... 51 Unpacking the DUSTTRAK Environmental Enclosure ................... 51 Spare Parts .................................................................................. 51 Parts Identification: Environmental Enclosure ............................. 52

SETTING-UP ............................................................................... 54 Installing the Aerosol or Respirable Aerosol Inlet ....................... 54 Install Water Trap Bottle .............................................................. 56 Correct Placement of Velcro Straps ............................................ 57 Install DUSTTRAK Monitor into Environmental Enclosure ............. 57 Connecting Tubing ...................................................................... 59 Supplying Power to the DUSTTRAK Aerosol Monitor .................... 59

Using the External Battery Pack ........................................... 60 Install External Battery Pack ................................................. 60

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Mounting to a Surveyor Tripod .................................................... 61 Downloading a Data File ............................................................. 62 Real-Time Monitoring .................................................................. 62 Setting-up TRAKPROTM Data Analysis Software .......................... 62 Transporting the Environmental Enclosure ................................. 63 Wiring the Analog/Alarm Cable in the Enclosure ........................ 63

OPERATION ............................................................................... 64 Overview ...................................................................................... 64 How to Properly Orient the Environmental Enclosure ................. 64 Changing and Re-charging the Battery Packs ............................ 64 Receiving Data from the DUSTTRAK Aerosol Monitor .................. 64 Zeroing the DUSTTRAK Aerosol Monitor ...................................... 65 Setting the Flow Rate .................................................................. 65 Locking the Environmental Enclosure ......................................... 65 Checklist for Sampling with the Environmental Enclosure .......... 66

MAINTENANCE .......................................................................... 67 Daily Maintenance Checks .......................................................... 67 Cleaning the Aerosol Inlet ........................................................... 67 Cleaning the Respirable Aerosol Inlet ......................................... 67 When to Change the Battery ....................................................... 67 Replacing the Battery Pack ......................................................... 67 Recharging the Battery Packs ..................................................... 68 Battery Pack Life ......................................................................... 68 Emptying the Water Trap ............................................................ 68 Storage Precautions .................................................................... 69

TROUBLESHOOTING THE ENVIRONMENTAL ENCLOSURE .............................................................................. 70

SPECIFICATIONS: ENVIRONMENTAL ENCLOSURE ............. 73 INDEX ................................................................................................ 75 AVAILABLE APPLICATION NOTES

DUSTTRAK, Theory of Operation ........................................... ITI-036 Frequently Asked Questions: DUSTTRAK Aerosol

Monitor .............................................................................. ITI-039 Serial Interface Commands and Connections:

Model 8520 ....................................................................... ITI-044 DUSTTRAK Analog Output ..................................................... ITI-073 DUSTTRAK Alarm Output ....................................................... ITI-074

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To obtain any of the listed Application Notes, contact TSI at: U.S. (800) 874-2811/(651) 490-2811, Fax: (651) 490-3824 International (001 651) 490-2811, Fax: (001 651) 490-3824

These Application Notes can also be found under TSIs web site: http://www.tsi.com

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Safety Information When operated according to the manufacturers instruction, this device is a Class I laser product as defined by U.S. Department of Health and Human Services standards under the Radiation Control for Health and Safety Act of 1968. A certification and identification label like the one shown below is affixed to each instrument.

There are no user-serviceable parts inside this instrument. Performing services other than those described in this manual may result in exposure to harmful (invisible) laser radiation. A warning label like the one shown below is affixed to the internal laser device.

DANGER: INVISIBLE LASER RADIATION WHEN OPEN. AVOID DIRECT EXPOSURE TO BEAM.

WARNING: NO USER SERVICEABLE PARTS INSIDE. REFER SERVICING

TO QUALIFIED PERSONNEL.

!

W A R N I N G The DUSTTRAK monitor Alarm Output function should not be used to detect hazardous conditions or to provide an alarm for protecting human life, health, or safety.

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1

Chapter 1 Unpacking and Parts Identification

Carefully unpack the Model 8520 DUSTTRAKTM Aerosol Monitor from the shipping container. Use the tables and illustrations below to make certain that there are no missing components. Contact TSI immediately if anything is missing or damaged.

Unpacking the DUSTTRAK Aerosol Monitor Compare all the components you received with those listed in the table below. If any parts are missing, contact TSI.

Quantity Item Description Part/Model 1 Model 8520 Aerosol Monitor 8520 1 Carrying Case 800686 4 C-size Alkaline Batteries 1208018 1 AC adapter

115 V, NEMA-1-15 230 V, Eur., CEE 7/16 230 V, Great Britain 240 V, Australian

2613033 2613078 800169 2613105

1 Data Analysis Software CD-ROM 800700 1 Zero Filter 800663 1 Computer Cable, 9-pin to RJ-45 800563 1 25-Pin to 9-Pin Serial Cable Adapter 962003 1 Model 8520 DUSTTRAK Aerosol Monitor

Operation and Service Manual 1980198

1 Calibration Certificate 1 10 mm Nylon Dorr-Oliver Cyclone 800665 1 Flowmeter, 02.5 L/min 800669

4 feet Plastic Tubing, 1/4 in I.D. 800668 1 Small Screwdriver 800661 1 Sample Nozzle Removal Tool 800662 8 Spare Internal Filter Element 1602188 1 Wrist Strap 2913028 1 Shoulder Strap 2913120 1 Sample Nozzle Cleaning Brush 800699

10 Cotton Swab 1 Inlet Nozzle, 2.5 m 1508112 1 Inlet Nozzle, 1.0 m 1508113 1 Impactor Plate 1508114 1 Tube, Grease 801163 1 Analog Output/Alarm:connector, with cable 801652

Chapter 1 2

Parts Identification for the DUSTTRAK Aerosol Monitor Figures 11 and 12 identify the parts of the Model 8520 DUSTTRAK Aerosol Monitor. Become familiar with these components before proceeding.

Figure 11: Top and Front of the DUSTTRAK Monitor

1. Display 7. External Power Socket 2. Keypad 8. Sample Inlet Nozzle and Port 3. Battery Cover 9. Flow Adjustment Screw 4. Battery Cover

Thumb Screw 10. Analog Output/Alarm

Connector 5. Data Port 11. Cyclone Holder Clip 6. Display/Keypad

Lockout Switch 12. Exhaust Port

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1

3

4

5 6 7

8 9

11 12 10

Unpacking and Parts Identification 3

Figure 12: DUSTTRAK Aerosol Monitor Accessories

1. Zero Filter 9. AC Adapter 2. Flowmeter 10. Cyclone 3. Wrist Strap 11. 25-Pin to 9-Pin Adapter 4. 2.5 m Inlet Nozzle 12. Shoulder Strap 5. 1.0 m Inlet Nozzle 13. Sample Tube Cleaning Brush 6. Impactor Plate 14. Sample Tube Removal Tool 7. Grease 15. Internal Filter Elements 8. Computer Cable 16. Analog/Alarm Cable (not

shown)

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9 10

11 12 13

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4 5 6 7

Chapter 1 4

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Chapter 2 Setting-Up

Supplying Power to the DUSTTRAK Aerosol Monitor The Model 8520 DUSTTRAKTM Aerosol Monitor must be powered in one of two ways: four size C batteries or the supplied AC adapter.

Installing the Batteries Remove the battery cover and slide the battery holder out of the battery compartment and insert four size C batteries. Hold the wires out of the way and slide the battery holder back into the battery compartment. Tuck the wires in and then re-install the battery cover (see Figure 21).

Figure 21: Tuck the Wires In and Close the Cover

Using the AC Adapter The AC adapter allows you to power the DUSTTRAK monitor from an AC wall outlet. When using the AC adapter, the batteries (if installed) will be bypassed. The AC adapter will not charge the batteries. The DUSTTRAK monitor has an internal, non-user accessible battery that is used to keep logged data intact when power is turned off. Changing the C-size batteries or disconnecting the AC adapter will not cause data to be lost. This battery will last for years. TSI will install a new battery, if necessary, when the unit is returned to the factory for service.

Chapter 2 6

Instrument Setup The DUSTTRAK monitor comes with special software called TRAKPROTM Data Analysis Software, which is designed to provide you with maximum flexibility and power when using the DUSTTRAK monitor. The following sections describe how to install the software and set up the computer.

Setting-up TRAKPRO Data Analysis Software TRAKPRO software contains a very comprehensive Help Function. This utility provides all the necessary information to guide you in all aspects of software operation.

Connecting the DUSTTRAK Aerosol Monitor to the Computer Each DUSTTRAK monitor comes equipped with an RS-232 cable and a 25-pin to 9-pin serial cable adapter. One end of the cable is a 25-pin D subminiature connector labeled COMPUTER; the other end is an RJ-45 modular connector that connects with the logging instrument. Serial port connectors always have pins (male) on the computer side.

1. Locate an available serial port on your computer: COM1, COM2, COM3, or COM4.

2. If the port has a 25-pin connector, you do not need the adapter. If the port has a 9-pin connector, plug the 25-pin end of the adapter into the RS-232 cable.

3. Connect the RS-232 cable to the available serial port on your computer.

4. Connect the RJ-45 connector to the DUSTTRAK monitor.

Set-Up the Communications Port To communicate with the DUSTTRAK monitor, the software must be configured for the proper COM port. The TRAKPRO software can be manually set to operate on a specific COM port, or it can automatically find a DUSTTRAK monitor that is attached to any COM port. To set up the COM port, do the following:

1. Turn on the DUSTTRAK monitor and start the TRAKPRO software.

2. Select Communications from the Instrument Setup menu. The following dialog is displayed:

Setting-Up 7

3. Select the following: Serial Port

Select the name of the serial port to which the logging device is connected: COM1, COM2, COM3, or COM4.

Baud Rate

Select the baud rate for the port. Higher baud rates are recommended to transfer data at a faster rate. Select a lower baud rate only if you are having trouble communicating at a higher rate.

4. Select Test to verify that you have set up the communications port

properly. The system displays an informative message indicating whether it was able to establish communications.

5. As an alternate, you can select Find Port, to have the TRAKPRO software search the available COM ports, looking for an attached DUSTTRAK monitor.

6. Select OK to accept the setup or Cancel to discard the changes. Note: Some computers do not communicate reliably at baud rates

above 9600.

Setting the Real-Time Clock The DUSTTRAK monitor has an internal real-time clock that keeps track of the time of day (The format is HH:MM where HH is the hour in 24-hour format and the MM is minutes) and the date. It is very important for the DUSTTRAK monitor to have the time and date correctly set; otherwise, date and time stamping of recorded data and calibrations will not be correct. There are two ways to set the time and date. The first is to use the supplied TRAKPROTM Data Analysis Software.

Chapter 2 8

Programming the Date/Time Using TRAKPRO Software To program the DUSTTRAK monitor date and time:

1. Make sure the DUSTTRAK monitor is connected to the computer and turned on.

2. Select Parameters, then Clock from the Instrument Setup menu. The TRAKPRO software retrieves the current date and time settings from the DUSTTRAK monitor and displays them in the following dialog:

3. The system date and time (from the computer) can be transferred to the DUSTTRAK monitor using the arrows keys. Alternately, the date and time can be manually entered into the dialog box.

4. Select Send to reprogram the DUSTTRAK monitor. Manually Setting the Real-Time Clock To set the time and date with the keypad, you must press and hold the SAMPLE key while the DUSTTRAK monitor displays the time of day during its power-up. Release when the DUSTTRAK monitor beeps. You will have an opportunity to view and/or change the hours, minutes, year, month, and day of month in sequence. Use the up and down arrow keys () to change a setting. Use the SAMPLE key to store each setting and advance to the next one.

Connecting the Optional Portable Printer To connect the portable printer to the DUSTTRAK monitor, locate Printer Interface Cable and connect the 9-pin end labeled PRINTER to the printer and the other end to the data port on the DUSTTRAK. monitor Always turn the DUSTTRAK monitor on BEFORE the printer. If the printer prints question marks (??????), asterisks (******), or random characters, reset it by turning

05/09/2006 05/09/2006

Setting-Up 9

it off and then on again. If necessary, refer to the Portable Printer Operation and Service Manual.

Connecting/Wiring the Analog/Alarm Output Connector The Model 8520 DUSTTRAK Aerosol Monitor is capable of providing an analog output voltage signal that is proportional to the displayed concentration. It also contains a switch closure that is tied to an alarm value (see Chapter 3, Operation, for complete specifications and operational information for these features). The DUSTTRAK monitor is supplied with an output cable. The cable contains a 4-pin, mini-DIN connector. See Figure 2-2 below.

1. Analog Ground (-) 3. Alarm Positive (+) 2. Analog Output (+) 4. Alarm Ground (-)

Figure 22: Analog/Alarm Connector Pin-Outs

Since every application of this function will have unique requirements, the customer is responsible for making connections to their own equipment. The output cable contains a label, showing the wiring diagram/pin-outs. Please see TSI Application Notes ITI-073 and ITI-074 for complete information and examples of wiring and using the Analog/Alarm Outputs. These Application Notes are available at the TSI website, http://www.tsi.com.

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Chapter 2 10

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Chapter 3 Operation

Overview The Model 8520 DUSTTRAKTM Aerosol Monitor has four modes of operation, Survey, LOG 1, LOG 2, and LOG 3. When the DUSTTRAK monitor is first turned on it will be in Survey mode, which is used to display real-time readings and to determine statistics such as average, minimum, and maximum readings. LOG 1 mode is used to record individual data points for later analysis using a fixed protocol. LOG 2 and LOG 3 modes have a user-defined protocol, set up using TRAKPROTM Data Analysis Software. TRAKPRO software is used for analysis of data taken in any of the three LOG modes, but cannot be used on samples taken in Survey mode.

DUSTTRAK Aerosol Monitor Keypad Functions When pressing the keys on the front panel, the DUSTTRAK monitor beeps to confirm the function. If you press a key and the DUSTTRAK monitor does not beep, the DUSTTRAK monitor does not allow that function during the selected sampling mode.

ON/OFF Key Press the ON/OFF key to power the DUSTTRAK monitor. The DUSTTRAK monitor immediately begins an internal self-check, while illuminating all the display digits and symbols. If a problem is detected, the display shows the message SERVICE along with a number to indicate that the DUSTTRAK monitor requires servicing. Refer to the Chapter 5: Troubleshooting, for information regarding service numbers. If the SERVICE message appears, the DUSTTRAK monitor pauses until any key is pressed. When the DUSTTRAK monitor completes its internal self-check, it displays the approximate percentage of battery life remaining. The DUSTTRAK monitor displays the battery symbol + when the battery voltage becomes very low. After the battery symbol appears, the DUSTTRAK monitor runs for approximately 60 minutes before displaying the message LO (for a few seconds) and then automatically turning off. This feature is accurate for alkaline batteries only.

Chapter 3 12

Note: The percentage life remaining will not be accurate for NiCd batteries. The battery symbol appears when battery voltage becomes low, but the DUSTTRAK monitor runs considerably less than 60 minutes before displaying the message LO and turning off.

Figure 31: DUSTTRAK Display with All Elements Shown

After displaying the percentage of battery life remaining, the current time set on the internal real-time clock is displayed. When the self-check is complete, the DUSTTRAK monitor will be in Survey mode.

SAMPLE Key Press the SAMPLE key to start/stop data sampling. The word SAMPLE appears in the upper right corner of the display while the DUSTTRAK monitor is taking a sample. When sampling is stopped, the DUSTTRAK monitor automatically scrolls through statistics for the sample that just ended.

TIME CONSTANT Key Momentarily press and release the TIME CONSTANT key to view the current time-constant. To change the time-constant, press and hold the key down. The available time-constant choices will scroll on the display. When the desired value is displayed, immediately release the key. The time-constant is actually an averaging period. The DUSTTRAK monitor display is always updated every second. However, the reading displayed is the average reading over the last time-constant period. For example, if the current time-constant is set to 10-seconds, the display shows readings averaged over the previous 10 seconds, updated every second. This is also called a 10-second moving average. As configured at the factory, the available time-constant values are 1, 5, 10, 15, and 30 seconds. The internal list of time-constant values can be altered using TRAKPRO Data Analysis Software supplied with the DUSTTRAK monitor. The range of time constants allowed is 160 seconds. See the following instructions.

Operation 13

Programming the Available Time Constants To program the list of time constants using TRAKPRO Data Analysis Software:

1. Make sure the DUSTTRAK monitor is connected to the computer and turned on.

2. Select Parameters, then Time Constants from the Instrument Setup menu. TRAKPRO software retrieves the current time constant settings from the DUSTTRAK monitor and displays them in the following dialog:

3. Enter a value for each of the five available time constants. (The range is

limited to 1-60 seconds.)

4. Select Send. The DUSTTRAK monitor is reprogrammed to offer the time constants you have specified.

STATISTICS Key Use the STATISTICS key to sequentially view the average, minimum, and maximum readings as well as the elapsed time of the most recently sampled data. If one of the LOG modes is active, a test identification number will be displayed also. Press the STATISTICS key once to display the average reading, again to display the minimum reading, again to display the maximum reading, and again to display the elapsed time for that sample (and again for the test ID if in LOG mode). If you press the STATISTICS key a fifth time (sixth time if in LOG mode), the DUSTTRAK monitor switches back into the currently selected measuring mode. You must sequence through all four statistic displays (i.e., press the STATISTICS key five

Chapter 3 14

times, six if in LOG mode) before the DUSTTRAK monitor goes back into the measuring mode.

PRINT Key Use the PRINT key to print information on the optional Portable Printer. The information printed will be different depending on what the DUSTTRAK monitor is currently doing. When the DUSTTRAK monitor is displaying real-time readings, pressing the PRINT key causes the reading to be printed along with the time and date. Each time the PRINT key is pressed, one reading will print. The reading printed reflects the current time-constant; therefore, it is the same as the displayed reading. When the DUSTTRAK monitor is displaying any statistic, pressing the PRINT key causes the current statistics to print. When the DUSTTRAK monitor is in one of the LOG modes and is idle (%MEMORY is displayed), pressing the PRINT key causes the logging setup for the current LOG mode to print. During the power-up sequence, if you press and hold the PRINT key after the time is displayed, a printout will be generated showing certain system information (printer must be connected and turned on).

SAMPLING MODE Key The SAMPLING MODE key allows you to select among the four sampling modes: Survey, LOG 1, LOG 2, and LOG 3. Each time you press the SAMPLING MODE key, the DUSTTRAK monitor sequences to the next mode. When the DUSTTRAK monitor is in Survey mode, the current measurement will be shown on the display. When one of the LOG modes is selected, the LOG mode number, i.e. LOG 1, LOG 2, or LOG 3 will be displayed along with the percentage of free memory available.

Survey Mode When the DUSTTRAK monitor is first turned on, it will always be in Survey mode. Survey mode allows you to make real-time measurements of aerosol concentration, and to obtain statistics for that sample. The statistics include the average, minimum, and maximum values, as well as the elapsed time for that sample. Individual data points are not recorded (this can be done in any of the LOG modes). Each new sample taken in Survey mode clears the previous sample data from memory. Data taken in Survey mode remains in memory until another sample is made, or until samples are taken in one of the LOG modes. Turning the

Operation 15

DUSTTRAK monitor off will not erase data. Use the SAMPLE key to start and stop a sample.

LOG Modes There are three LOG modes: LOG 1, LOG 2, and LOG 3. When one of these modes is selected using the SAMPLING MODE key, the LOG mode number will be listed at the top of the display. The LOG modes allow you to record aerosol concentration data points for later retrieval and analysis using the software provided with the instrument. Use the SAMPLE key to start and stop recording. The word RECORDING appears at the top of the display when recording is in progress. The frequency that data is recorded can be set for LOG 1 mode with the LOGGING INTERVAL key. Use TRAKPRO software for LOG 2 and LOG 3 modes. Data recorded using one of the LOG modes can only be erased by using the CLEAR MEMORY key. Turning the DUSTTRAK monitor off will not erase data. Recording another sample with one of the LOG modes without clearing memory first will cause new data to be added to the existing data (using a new test ID).

CLEAR MEMORY Key Use the CLEAR MEMORY key to erase all data. The CLEAR MEMORY key will not respond unless the DUSTTRAK monitor is first put into one of the three LOG modes by using the SAMPLING MODE key.

Note: Before clearing memory, you should first download the data to a computer through the TRAKPRO software. There is only one block of memory in the DUSTTRAK monitor. Clearing the memory for one LOG mode clears memory for all LOG modes.

To clear memory, press and hold the CLEAR MEMORY key until the countdown reaches zero, then release quickly. This prevents accidental erasure of data. Releasing the key too soon or too late prevents memory from being cleared.

LOGGING INTERVAL Key Use the LOGGING INTERVAL key to view or set the frequency/averaging period for recording data in LOG 1 mode or to view the current interval setting in LOG 2 and LOG 3 mode. Use TRAKPRO software to set the logging interval for LOG 2 and LOG 3 mode (see following section). The LOGGING INTERVAL key will not respond unless the DUSTTRAK monitor is first put into one of the three logging modes. Press the LOGGING

Chapter 3 16

INTERVAL key momentarily to view the current logging interval. Press and hold the LOGGING INTERVAL key to sequence through the available choices and release the key when the desired interval is on the display (LOG 1 mode only). The logging interval is both a frequency and an averaging period. For example, when the logging interval is set to 30-minutes, readings will be recorded at 30-minute intervals. Each reading will be the average value measured over a 30-minute interval. As shipped from the factory, the available logging intervals for LOG 1 mode are 1 second, 1 minute, 5 minutes, 15 minutes, and 30 minutes. Use the TRAKPRO Data Analysis Software to alter these values.

Programming the Logging Intervals using TRAKPRO Software To program the list of logging intervals available for LOG 1 mode:

1. Make sure the DUSTTRAK monitor is connected to the computer and turned on.

2. Select Parameters, then Logging Intervals from the Instrument Setup menu. TRAKPRO software retrieves the current logging intervals from the DUSTTRAK monitor and displays them in the following dialog:

3. Enter a value for each of the five available logging intervals (the range

is from 1 second to 59 minutes and 59 seconds).

4. Select Send. The DUSTTRAK monitor is reprogrammed to offer the logging intervals you have specified.

Operation 17

and Keys The two arrow keys are used to adjust readings when calibrating the DUSTTRAK monitor and for adjusting the time and date for the internal real-time clock.

CALIBRATE Key Use the CALIBRATE key to put the DUSTTRAK monitor into calibration mode. See Chapter 4, Maintenance for details on how to calibrate.

Display/Keypad Lockout Switch Recording data over extended time periods often requires leaving the DUSTTRAK monitor unattended. To reduce the risk of having an unauthorized person either intentionally or inadvertently interrupt the measurements, you can lock the display and keypad. The lockout switch is on the backside of the DUSTTRAK monitor between the data port and the external power socket. It is a small slide switch and is recessed so that a pointed instrument must be used to move it. With the switch in the right side position (nearest the power socket), all keypad and display functions will work normally. With the switch in the left side position (closest to the data port), the display and keypad will go into lockout mode. There are two ways to use the lockout switch. You can lock the keypad after recording starts, or you can put the switch into the lockout position prior to when recording starts. If you select the second method, you will be able to operate all functions normally until the SAMPLE key is pressed in one of the LOG modes. At that time the keypad automatically locks. When the display and keypad are locked, the display shows the words RECORDING LOG X where X is the current LOG mode number.

Remote Sampling The DUSTTRAK Aerosol Monitor can be used for remote sampling by attaching a length of tubing to the inlet. For example, it can be set up for a test and hidden away where only the sample tubing extends into the area to be monitored. A 4-foot length of tubing is included with the DUSTTRAK monitor for remote sampling purposes.

Note: Using a sampling tube longer than 4 feet is not recommended because particle transport losses in the tube may adversely affect the measurement. Also, do not use Teflon or silicone tubing because they can cause significant transport losses. Tygon tubing is a good choice, as is metal tubing if it is grounded to dissipate static charges.

Tygon is a registered trademark of Norton company.

Chapter 3 18

Respirable Mass Sampling with the Cyclone The 10-mm Nylon Dorr-Oliver Cyclone included with your aerosol monitor can be used to discriminate between the respirable fraction and other portions of the ambient aerosol. Four micrometers (m) is internationally accepted as the 50 percent cut-off size for respirable aerosol mass. Particles larger than 4 m impact onto the surfaces of the upper respiratory tract and cannot reach the lungs. The cyclone accessory provided with the DUSTTRAK monitor is designed to provide a cut-off at 4 m. This is specified as a 50 percent cut-off at 4 m. The cyclone works by forcing the particle-laden air sample to swirl inside the cyclone body. Larger (higher mass) particles cannot follow the air stream and become trapped, while smaller particles stay in the air stream and pass through. When using the cyclone, you can assume that all particles smaller than the cut-off size pass through and all larger particles become trapped in the grit pot. The cut-off size for any cyclone is dependent on flow rate. It is very important that the sample flow rate through the DUSTTRAK monitor be set at 1.7 liters per minute (L/min). If some other flow rate is set, the cut-off size will not be at 4 m.

Using the Cyclone To use the cyclone, be sure that you have the black inlet nozzle in place and that the blue impactor plate is removed from the inlet. Then you must adjust the sample flow rate to 1.7 L/min. See Chapter 4: Maintenance, for details. After the flow rate is properly set, attach it to the DUSTTRAK monitor inlet port using the section of plastic tubing supplied with the cyclone. Slide the cyclone body into the holder provided on the back of the DUSTTRAK monitor. See Figure 32.

Operation 19

Figure 32: Connecting the Cyclone

1. DUSTTRAK Sample Inlet 3. Cyclone Holder 2. Cyclone

Using the 1.0 or 2.5 m Inlet Conditioners The two blue inlet nozzles appear similar to the standard black inlet nozzle but are engraved with their respective cut size. The blue nozzles should always be used with the blue impactor plate. The black nozzle has a cut size of 10 m and should never be used with the impactor plate. Install either the 1.0 or 2.5 m inlet conditioner as follows.

1. Turn the DUSTTRAK monitor off.

2. Remove the black inlet nozzle.

3. Evenly coat the center plateau of the blue impactor plate with a thin layer of the supplied grease (Figure 33). Avoid getting the grease on other parts of the impactor plate. If you do, simply wipe off the extra.

Notes: Do not use grease other than that supplied with this kit. This grease has been chosen for its low outgassing and good wicking properties to hold a large mass of particles.

The grease on the impactor plate increases the amount of time that you can sample before particle bounce begins to affect the impactor performance. Particle bounce results from particles not sticking to the impactor plate and falling back into the aerosol stream.

4. Insert the blue impactor plate into the DUSTTRAK monitor.

5. Select the blue nozzle with the cut size you want and make sure there is an O-ring inside.

1

2

3

Chapter 3 20

6. Thread the nozzle on the inlet.

7. Turn on the DUSTTRAK monitor and verify that the flow rate is at 1.7 L/min. You might need to make a small adjustment when you switch nozzles.

The DUSTTRAK monitor is calibrated to the respirable fraction of ISO 12103-1, A1 (formerly called ultrafine Arizona test dust or SAE ultrafine). To increase the accuracy while using the inlet conditioners, you will need to calibrate in the aerosol you wish to test. Please refer to the manual for calibration details.

Figure 33: Installing the 1.0 or 2.5 m Inlet Conditioners

Because of the much higher percentage of particles being removed from the stream when using the smaller cut-size inlets, you will need to clean the inlet more frequently than for the standard 10 m nozzle (black.) See maintenance schedule in Chapter 4 for the inlet cleaning frequency.

Using the 10 m Nozzle 1. Remove the blue nozzle and blue impactor plate.

Note: The blue impactor plate must be removed from the inlet when using the black nozzle. Performance of the 10 micrometer nozzle will be severely degraded if the impactor plate is not removed.

2. Thread the black nozzle onto the DUSTTRAK monitor inlet. 3. Verify that the flow rate is at 1.7 L/min. 4. The DUSTTRAK monitor now measures aerosol with an upper particle

size limit of 10 m.

Operation 21

Analog Output Newer models of the Model 8520 DUSTTRAK Aerosol Monitor contain an analog output feature. This means the instrument is capable of providing an analog voltage signal that is proportional to mass concentration.

Note: Before using this feature, it is important to read this operational section. For further information, please see Application Note ITI-073, which describes the Analog Output programming and operation. This Application Note is available at the TSI website, http://www.tsi.com.

Because the DUSTTRAK monitor measures aerosol over such a wide dynamic range, it is necessary to select the appropriate range before using the analog output feature. The instrument may be programmed to one of four options, using the TRAKPRO software. When shipped from the factory, the instrument is programmed to the lowest range. To select the analog output range, do the following:

1. Turn on the DUSTTRAK monitor and start the TRAKPRO software (version 3.2 or higher).

2. Select Parameters, Analog Output, from the Instrument Setup menu. The following dialog is displayed:

3. Select one of the four ranges, and press Send. Please note the following considerations when using the analog output feature. The analog output function is always On. You do not need to activate

this function. The interpretation of the analog output voltage is directly tied to the

chosen range. For example, at the lowest range, each 0.001 mg/m3 of

Chapter 3 22

aerosol is equivalent to 0.050 VDC. If the instrument display shows 0.018 mg/m3, the analog output voltage would be 18 x 0.050 VDC or 0.9 VDC (see Application Note ITI-073, for more specifications and examples).

Select the lowest range consistent with your desired application. For example, if you typically measure aerosol mass concentrations around 0.025 mg/m3, you should use the first range. This will provide you with the best resolution (strongest signal) corresponding to the mass concentration.

If your application involves high-mass concentrations (wood dust, etc.) you may want to choose the second or third range.

If the DUSTTRAK monitor measures mass concentrations that are greater than the selected range, the analog voltage will rail at 5.0 volts (maximum output; no change in signal beyond that point).

All of the ranges are referenced back to zero mg/m3.

Alarm Output Newer models of the DUSTTRAK Aerosol Monitor contain an alarm output feature. This means the instrument is capable of providing an alarm signal when the measured mass concentration exceeds a certain threshold. Note: Before using this feature, it is important to read this operational

section. For further information, please see Application Note ITI-074, which describes the Alarm Output programming and operation. This Application Note is available at the TSI website, http://www.tsi.com .

Operation 23

Alarm Output Specifications Please note the following considerations when using the analog output feature.

!

W A R N I N G The DUSTTRAK monitor Alarm Output function should not be used to detect hazardous conditions or to provide an alarm for protecting human life, health or safety.

The alarm output function default status is Off. You must activate this function and set the alarm level, before using the alarm output (see section below, on programming the Alarm Output).

You must supply your own powered alarm system. The DUSTTRAK monitor only contains a switch that closes (activates) the alarm, when the detected levels exceed the threshold.

The user alarm must be DC-powered only! The alarm system must not exceed a maximum supply voltage rating of 15 VDC or a current draw of 1 amp.

!

C a u t i o n The alarm switch must not be wired to AC power! Failure to properly install the user alarm could damage the DUSTTRAK instrument and/or void the instrument warranty! Please read and follow all instructions before wiring or operating the user alarm.

The alarm switch contained within the DUSTTRAK monitor has an

electrical polarity. It must be wired with the supply voltage connected to the positive pole. If the user alarm is wired with reverse polarity, it will not function properly.

The alarm threshold must be set between the values of 0.002 and 100 mg/m3.

The alarm switch will turn on the instant the setpoint is reached. It will remain latched for a minimum of 5 seconds.

While the alarm is triggered, the DUSTTRAK monitors internal beeper will sound once per second, and the display will alternately exhibit the characters AL to indicate an alarm condition.

The alarm switch will turn off when the measured concentration falls 5% below the setpoint (dead-band).

The alarm output function operates totally independently of the analog output.

Chapter 3 24

Programming the Alarm Setpoint

To program the alarm output function, do the following:

1. Turn on the DUSTTRAK monitor and start the TRAKPRO software (version 3.2 or higher).

2. Select Parameters, Alarm Setpoint, from the Instrument Setup menu. The following dialog is displayed:

3. Turn On the alarm function by checking the Alarm Enabled check box. Enter a value within the acceptable range. In this example, the DUSTTRAK monitor is programmed to a setting of 0.100 mg/m3. Press the Send button, to program the instrument.

Upgrading the DUSTTRAK Aerosol Monitor to Add Analog and Alarm Functions

The newest version of the DUSTTRAK Aerosol Monitor contains the analog output and alarm functions. Older instruments may be hardware compatible with these functions and may only require a factory upgrade to install these features. Instruments manufactured before August 1999 are not capable of being upgraded to add these features. These three scenarios are summarized below.

Identifying an Instrument with Analog/Alarm Functions If your instrument contains an Analog/Alarm Output connector on the back of the instrument, it is fully functional for both analog and alarm output functions.

Operation 25

Identifying an Instrument that may be Upgraded to Add Analog/Alarm Functions If your DUSTTRAK Aerosol Monitor was manufactured after August 1999 (serial number 21960 or later) and does not contain the analog/alarm output connector, it may be upgraded at the factory to add this feature. To verify this status, simply attach the instrument to the TRAKPRO software and attempt to program the Analog or Alarm Setpoint functions. You should receive the following message:

This instrument may be returned to the factory, for a Cleaning, Calibration and Upgrade (there is a charge for this service). Identifying an Instrument That May Not Be Upgraded If your DUSTTRAK Aerosol Monitor was manufactured prior to August 1999 (serial number 21959 or earlier), it is not hardware compatible with these functions. It is not possible to upgrade these instruments to add analog/alarm functions. To verify this status, simply attach the instrument to the TRAKPRO software and attempt to program the Analog or Alarm Setpoint functions. You should receive the following message:

Chapter 3 26

Programming Advanced Modes: LOG 2 and LOG 3 Use LOG 2 or LOG 3 modes for unattended recording and setting user protocols. With LOG 2 and LOG 3 modes you can set the start date, start time, test length, logging interval, number of tests and the time delay between tests. All or selected parameters can be set.

To program a protocol for LOG 2 or LOG 3 mode: 1. Make sure the DUSTTRAK monitor is connected to the computer and

turned on. 2. Select Logging Setup from the Instrument Setup menu. The TRAKPRO

software retrieves the current settings for LOG 2 and LOG 3 modes from the DUSTTRAK monitor and displays them in the following dialog:

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Operation 27

The following table summarizes the information displayed in the DUSTTRAK Logging Protocols dialog box: Serial Number Displays the serial number of the logging

instrument. Number of tests logged

Displays the number of tests currently logged and stored in the logging instrument.

Available Memory (%)

Displays the percent of available memory in the logging instrument.

LOG 2 and LOG 3 Mode Protocols Channels Displays the channels selected for sampling in

LOG 2 and LOG 3 modes. Start Date Displays the start date for LOG 2 and LOG 3

modes. Start Time Displays the start time for LOG 2 and LOG 3

modes. Log interval Displays the log interval for LOG 2 and LOG

3 modes. Test length Displays the test length for LOG 2 and LOG 3

modes. Number of tests Displays the number of tests for LOG 2 and

LOG 3 modes. Time between tests

Displays the time between tests for LOG 2 and LOG 3 modes.

Percent memory required.

Displays the percent of logger memory required to perform a LOG 2 or a LOG 3 mode sample. To store the results of a LOG 2 or LOG 3 mode sample, the Available Memory must be equal to or greater than the Percent memory required.

Chapter 3 28

3. Enter the following for LOG 2 and LOG 3 modes: Channels Select the channels for which you want to log

data. In the case of the DUSTTRAK monitor, there is only one channel to select: Aerosol.

Start Date Start Time

Enter the date and time to begin the sample: If you enter a blank for a start date, the

sample begins whenever the specified start time occurs.

If you enter a blank for the start time, both start date and start time are ignored, and the sample begins when the operator manually starts the sample.

Log interval Enter the log interval to use for the test. Test length Enter the length for the sample:

If you enter a value, the instrument automatically turns off when the last test is complete.

If you enter a blank, the operator must manually stop the sample.

Number of tests Enter the number of tests to perform. Time between tests

If you have specified more than one Number of tests, enter the time between tests. If you enter 0 or blank, the next test is started immediately after the last test is complete.

While you are entering values for LOG 2 and LOG 3 modes, the

Percent Memory Required is dynamically updated to show the amount of logger memory required to take the programmed sample. If the protocol you have defined requires more than 100% of memory, you can decrease the amount of memory required by manipulating the following protocol parameters: Increase the logging interval. Decrease the length for the test. Decrease the number of tests.

The settings for each LOG mode must not require more than 100% of the logger memory.

Note: If the Percent memory required is greater than the Available memory, the logging instrument automatically stops the test when memory is full.

4. When you have finished defining the parameters for LOG 2 and LOG 3 modes, select Send.

Operation 29

5. You can now disconnect the DUSTTRAK monitor and cable from the computer.

Sample Protocol for LOG 2 and LOG 3 Modes The following steps describe how to program a sample protocol for LOG 2 or LOG 3 mode. The sample protocol for LOG 2 is set to take unattended aerosol readings for one day, 11/02/2004. The logging sample begins at 8:00 a.m. and continues for eight hours. The sample protocol for LOG 3 is set up to take unattended aerosol readings for two days, beginning on 11/02/2004. The logging sample begins at 8:00 a.m. and continues for eight hours. The instrument is off for 16 hours, and then repeats the eight hours test on the following day. The following graphic gives the appearance of the dialog box displayed in the TRAKPRO software, with these particular logging parameters.

To program this logging example, do the following:

1. Make sure the DUSTTRAK monitor is connected to the computer and turned on.

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Chapter 3 30

2. Select Logging Setup from the Instrument Setup menu. The TRAKPRO software retrieves the current settings for LOG 2 and LOG 3 modes from the DUSTTRAK monitor and displays them in the previous dialog.

3. Enter the following for LOG 2 and LOG 3: Setting LOG 2 LOG 3 Channels Aerosol Aerosol Start Date 05/09/2006 05/10/2006 Start Time 08:00 08:00 Log interval 01:00 05:00 Test length 00:08:00 00:08:00 Number of tests 1 2 Time between tests

00:00:00 00:16:00

4. Select Send. The logging instrument is programmed for the mode 2 and

mode 3 protocols.

5. Note that the LOG 2 test requires 1% of the available memory and LOG 3 requires less than 1% of the memory. A total of 100% of the memory is available for use.

6. You can now disconnect your DUSTTRAK monitor from the computer. Refer to other sections of this Operation and Service Manual for details on making measurements using LOG 2 and LOG 3 modes.

After programming the DUSTTRAK monitor with the TRAKPRO Data Analysis Software, take the DUSTTRAK monitor to the desired location and turn it on. Put it into LOG 2 or LOG 3 mode (whichever you programmed) using the SAMPLING MODE key. Press the SAMPLE key to initiate the program. If you have set a start time and/or date, the display toggles between the next TEST ID and the ELAPSED TIME 0 message. If the test start time is greater than one minute away, the DUSTTRAK monitor shuts off until one minute before the test start time. This indicates that the DUSTTRAK monitor is waiting until the programmed start time and dates occur. To prevent tampering, lockout the display and keypad at this time.

Things You Should Know About Taking Pre-Programmed Samples If you press the SAMPLE key during programmed operation, the program terminates (unless the keypad is locked).

Operation 31

If the programmed start time/date has already passed, pressing the SAMPLE key has no effect. The program will never execute.

It is always best to enter both a start time and start date! However, setting the start time but no start date causes the DUSTTRAK monitor to start at the specified time regardless of the date. The instrument may not shut down prior to beginning logging.

If no start time is set, the DUSTTRAK monitor waits for you to press the SAMPLE key and then starts sampling immediately.

If no test length is set, the DUSTTRAK monitor takes samples continuously until the SAMPLE key is pressed to stop sampling or until memory is full.

When a pre-programmed test ends, the DUSTTRAK monitor automatically shuts off.

Memory Considerations The DUSTTRAK monitor has a great deal of memory and you will not normally have to be concerned with running out. The DUSTTRAK monitor can store more than 31,000 data points. Therefore 1% of memory is about 310 data points. This should be considered when selecting a logging interval. Shorter logging intervals use memory more quickly than longer intervals. The logging interval and the available memory determine the maximum possible duration of a data logging session. The equation below can be used to determine any memory, recording time or logging interval restraints.

[ ][ ] [ ]Interval Logging315

Time Elapsed Memory%

(Note: Elapsed Time and Logging Interval are in units of minutes.)

Custom Calibrations In most situations, the DUSTTRAK monitor with its built-in data logger can provide very good information on how the concentration of an aerosol changes for different processes over time. Factory calibration to the respirable fraction of standard ISO 12103-1, A1 test dust (formerly Arizona Test Dust) allows comparisons between measurements where the source or type of dust is predominately the same. Because optical mass measurements are dependent upon particle size and material properties, there may be times in which a custom calibration would improve your accuracy for a specific aerosol.

Chapter 3 32

The DUSTTRAK monitor has several features to aid in obtaining good accuracy for a particular aerosol.

The DUSTTRAK monitors custom calibration factor can be changed through the instrument keypad. All future readings from the DUSTTRAK monitor will correspond to a specific aerosol until the calibration factor is changed back to the factory setting.

Custom calibration factors can be stored in a table and downloaded to the DUSTTRAK monitor using the TRAKPRO Data Analysis Software. All future measurements will correspond to a specific aerosol until the calibration factor is changed back to the factory setting.

A single set of logged data can be converted to data calibrated to a specific aerosol with the use of the TRAKPRO software. This conversion can be done by knowing either the true mass concentration for the logged data or the calibration factor for the aerosol. Future measurements will continue to be read and logged with the original calibration factor (normally 1.0) and will not be converted automatically.

All of these options require that you determine a true mass concentration (e.g., gravimetric analysis) for the aerosol you want to measure. The true mass concentration is used to calculate the custom calibration factor for that aerosol. Once you have a custom calibration factor, you can reuse it each time you make measurements in the same or similar aerosol environment.

Determining the Calibration Factor for a Specific Aerosol The DUSTTRAK monitor is factory calibrated to the respirable fraction of standard ISO 12103-1, A1 test dust. The DUSTTRAK monitor can be easily calibrated to any arbitrary aerosol by adjusting the custom calibration factor. The DUSTTRAK monitors custom calibration factor is assigned the value of 1.00 for the standard ISO test dust. This procedure describes how to determine the calibration factor for a specific aerosol. Using a value of 1.00 will always revert back to the factory calibration. To determine a new calibration factor you need some way of accurately measuring the concentration of aerosol, hereafter referred to as the reference instrument. A gravimetric analysis is often the best choice, though it is limited to nonvolatile aerosols. To make an accurate calibration you must simultaneously measure the aerosol concentration with the DUSTTRAK monitor and your reference instrument.

1. Zero the DUSTTRAK monitor as described in the Maintenance chapter.

Operation 33

2. Put the instrument in Log Mode 1.

3. Set the logging interval by pressing and holding the LOGGING INTERVAL button down. The default choices for the logging intervals can be reprogrammed using TRAKPRO software. One minute (i.e., 01:00) is often a good choice.

4. Locate the DUSTTRAK monitor and the reference sampler together so that they are measuring from the same area.

5. Start sampling aerosol with both instruments at the same time.

Note: Greater accuracy will be obtained with longer samples. The time you permit for sampling often depends on the reference instrument and characteristics of the measured aerosol. It may take some time to collect sufficient aerosol onto a filter cassette for accurate gravimetric analysis. Refer to instructions of your reference instrument for sampling times.

6. Stop sampling with both instruments at the same time.

7. Record the DUSTTRAK monitor average concentration. Press the STATISTICS key to view the average for the last test. If you wish to determine a custom calibration factor for this test only, you can instead receive the data into the TRAKPRO software.

8. Determine the mass concentration in mg/m3 from your reference instrument. For gravimetric sampling this means having the gravimetric sample weighed.

9. Compute the new calibration constant, NewCal, using the following formula:

CurrentCalionConcentratDustTrak ionConcentrat ReferenceNewCal

=

The calibration factor, OldCal, can be obtained from the DUSTTRAK monitor. In Survey mode, press and hold the CALIBRATE key down until the display counts down to zero. Release immediately when zero is reached and CALIBRATE ZERO appears on the display. If not, try again until it does. Press CALIBRATE again and the current calibration factor will be displayed with flashing up and down arrows. Record this value to make your calculation. Press CALIBRATE again to exit calibration mode.

Setting Custom Calibration Factor from Keypad

1. In Survey mode, press and hold the CALIBRATE key down until the DUSTTRAK monitor counts down to zero. Release the button

Chapter 3 34

immediately when zero is reached and CALIBRATE ZERO appears on the display. If not, try again until it does.

2. Press CALIBRATE again and the current calibration factor will be displayed with flashing up and down arrows.

3. Use the up and down arrows on the keypad to adjust the calibration factor. To revert back to factory calibration, set to 1.00.

4. Press SAMPLE to store the value and exit calibration mode, or press CALIBRATE to exit without saving the new value.

Setting Custom Calibration Factors using TRAKPRO Software The TRAKPRO software allows you to store several custom calibration factors along with a brief title for the aerosol or environment the calibration was taken. A calibration factor can be downloaded to the DUSTTRAK monitor when you want to make measurements of that aerosol or environment. All future measurements will be adjusted by the new custom calibration factor until you change it to some other value. To set this new custom calibration factor using TRAKPRO software, do the following:

1. Connect your DUSTTRAK monitor to the computer and start the TRAKPRO software.

2. Select DUSTTRAK Model 8520 from the Options menu. Or, select DUSTTRAK from list of available instruments on the Drop-Down menu on the menu bar.

3. Select Calibration in the Instrument Setup menu. The following dialog box is displayed.

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Operation 35

4. Click the Set DUSTTRAK Calibration button. The following dialog box is displayed.

5. Enter a new Calibration Factor along with a new Name and press

Add. This adds the new Calibration Factor to the list of available factors. In the example above, the Wood Dust factor, with a value of 1.45, was added to the list.

Note: This step does not automatically download the new value to the DUSTTRAK monitor. This must be done in a separate step.

6. Highlight the desired Defined Calibration factor (either the new one or a previous factor) by clicking on it, and press Send. This downloads the new Calibration Factor to the DUSTTRAK monitor. You can enter up to 25 different custom calibrations.

7. The DUSTTRAK monitor response for all subsequent measurements will be multiplied by the new factor. To reset the DUSTTRAK monitor to factory calibration, simply send the factory setting of 1.

Converting Stored Data to Calibrated Data A single set of logged data can be converted to data calibrated to a specific aerosol with the use of the TRAKPRO software. This conversion can be done by knowing either the true mass concentration for the logged data or the calibration factor for the aerosol. To perform this conversion, follow these steps: Note: This process converts existing data files using a new calibration

factor. It does not affect the current reading of the DUSTTRAK monitor. Future measurements will continue to be read and logged with the original calibration factor (normally 1.0) and will not be converted automatically.

1. Connect your DUSTTRAK monitor to the computer and start the TRAKPRO software.

Chapter 3 36

2. Select DustTrak Model 8520 from the Options menu under Software Configure. Or, select DustTrak from list of available instruments on the drop-down menu on the menu bar.

3. Open the file that contains the data to be converted. Highlight a single test within that data file.

4. Select Define DustTrak Calibration from the Options menu. The following dialog box is displayed.

5. Enter the New Mass Concentration value (in mg/m3). The New Calibration Factor is calculated and automatically updated. Press OK.

6. When you click OK, a new data set of the same name will be generated calibrated to the mass concentration that you entered. This data set will be appended to the same file. The original data remains.

7. If you want to adjust the data to a previously determined custom calibration factor without performing a gravimetric calibration, enter the new calibration factor. The New Mass Concentration automatically updates.

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37

Chapter 4 Maintenance The DUSTTRAK monitor can be maintained and calibrated in the field using the instructions below. Even so, TSI recommends that you return your DUSTTRAK monitor to the factory for annual calibration. For a reasonable fee, we will quickly clean and calibrate the unit and return it to you in as new working condition, along with a Certificate of Calibration. This annual checkup helps ensure that the DUSTTRAK monitor is always in good operating condition. The DUSTTRAK monitor is factory calibrated to the standard ISO 12103-1, A1 test dust (formerly Arizona Test Dust). The calibration data is stored internally and cannot be accessed by you. This standard test dust is used because of its wide particle size distribution. This makes the internal calibration representative of an average of most types of ambient aerosol you might encounter. For many applications, the factory calibration provides accurate measurements. There may be times when more accurate mass concentration data is needed because the aerosol being sampled is significantly different than the standard ISO test dust. To accommodate such a measurement, the DUSTTRAK monitor has been designed to allow for field calibration.

Note: There are no user-serviceable parts inside this instrument. TSI recommends that you return the DUSTTRAK monitor to the factory for any required maintenance or service not described in this manual.

Maintenance Schedule Your Model 8520 DUSTTRAK Aerosol Monitor requires maintenance on a regular basis. Table 41 lists the factory recommended maintenance schedule. Some maintenance items are required each time the DUSTTRAK monitor is used or on an annual basis. Other items are scheduled according to how much aerosol is drawn through the instrument. For example, cleaning the inlet sample tube is recommended after 350 hours of sampling a 1 mg/m3 concentration of aerosol. This recommendation should be pro-rated according to how the instrument is used. 350 hours at 1 mg/m3 is the same amount of aerosol as 700 hours at 0.5 mg/m3 or 175 hours at 2 mg/m3, etc.

Chapter 4 38

When using the 1.0 or 2.5 m inlet nozzles you need to clean the inlet more frequently than for the standard 10 m nozzle (black) because of the much higher percentage of particles being removed from the stream. Table 41 represents estimates of how long you can run before cleaning is necessary. The actual time you can run between cleanings varies with the size distribution of particles you are measuring. Table 41. Recommended Maintenance Schedule Item Frequency Perform zero check Daily (or before long tests) Clean 1.0 m nozzle 5 hr. at 1 mg/m3* Clean 2.5 m nozzle 30 hr. at 1 mg/m3* Clean 10 m nozzle, inlet, and sample tube 350 hr. at 1 mg/m3* Replace internal filters 700 hr. at 1 mg/m3* Clean cyclone Before each use Return to factory for cleaning and calibration

Annually

*Pro-rated, see discussion above. The DUSTTRAK monitor keeps track of the accumulated amount of aerosol drawn through it since its last cleaning. When sample tube cleaning or internal filter replacement is due, the display shows the message SERVICE 4 or SERVICE 5, respectively, during power-up. Press any key to bypass the message, but be sure to perform the maintenance procedures at your earliest convenience. TSI recommends that you perform a zero check each day the DUSTTRAK monitor is used, before running any extended tests, and after the instrument experiences a significant environmental change. Examples of significant environmental changes would be ambient temperature changes that exceed 15 F (8 C) or moving from locations with high aerosol concentrations to low concentrations.

Zero Checking/Re-Zeroing

1. Put the DUSTTRAK monitor in Survey mode.

2. Put zero filter on aerosol sample inlet. See Figure 41.

3. Set the time-constant to 10 seconds. Press and hold the TIME CONSTANT key until 10 is displayed, then release.

4. Wait 1060 seconds for displayed values to settle to zero.

5. If the displayed value is between -0.001 and +0.001 mg/m3, the DUSTTRAK monitor does not need adjustment. If the displayed value exceeds this limit, follow steps 7 to 9 below to re-zero the instrument.

Maintenance 39

Note: Negative mass concentration readings are an indication that the DUSTTRAK monitor needs to be re-zeroed. The negative reading of 0.001 in step 5 above is the only time when a negative reading is acceptable.

Figure 41: Zero Checking the DUSTTRAK Aerosol Monitor

6. Press and hold the CALIBRATE key and wait for the displayed countdown to reach 0, then immediately release the key. The message CALIBRATE ZERO is displayed if not, try again.

7. Press the SAMPLE key and wait for the 60-second countdown. When the countdown is completed, the current calibration constant will be displayed.

8. Press the CALIBRATE key again to return to survey mode. The re-zeroing process is now completed.

Cleaning the 1.0 m and 2.5 m Inlet Conditioners

1. Turn the DUSTTRAK monitor off.

2. Remove the inlet nozzle and impactor plate.

3. Wipe the old grease and other residue off from the impactor plate and nozzle. Once the nozzle and impactor plate are removed from the DUSTTRAK monitor, compressed air can be used to blow them off. Do not blow directly into the DUSTTRAK inlet. You can use isopropanol or soap and water to clean the parts, but be sure they are dry before reassembly.

4. Inspect the inlet for residue and clean as necessary.

5. Reapply grease to the impactor plate.

6. Reassemble the inlet conditioners.

Chapter 4 40

Cleaning the 10 m Inlet and Sample Tube The aerosol inlet needs to be cleaned regularly. The inlet nozzle should be cleaned based on the schedule in Table 41 above or especially when changing from very high concentrations of aerosols to low concentrations. The SERVICE 4 message will be displayed during power-up when nozzle cleaning is due. The DUSTTRAK monitor pauses when any of the service messages come on. Press any key to bypass the message and continue. The SERVICE 4 message is a one-time indicator to remind you that inlet port cleaning is due. This message will automatically reset.

1. Move to a relatively clean environment. (Aerosol concentration less than 0.1 mg/m3.)

2. Turn the DUSTTRAK monitor off.

Figure 42: Exploded View of Inlet Assembly

3. Remove the sample inlet nozzle and O-ring. The O-ring will usually stay inside the nozzle.

4. Use the sample tube removal tool to unscrew the tube from the inside of the inlet port. The cross-pattern on one end of the tool mates with the end of the sample tube.

5. Use the hook end of the tool to pull the sample tube out of the inlet port.

6. Clean the sample tube and inlet port. A cotton swab can be used to clean the inside of the inlet port, cap, O-ring, and ends of the tube. The swabs can be dampened with water or a light solvent (e.g., isopropanol).

Note: Do not use compressed air to clean the inlet area. Compressed air forces particulates into the optics chamber and contaminates the optics.

Maintenance 41

The inside of the sample tube can be cleaned using the sample tube cleaning brush provided, along with a light solvent. Dry the tube by blowing it out with compressed air, or let it air-dry thoroughly. Be careful not to blow particles into the DUSTTRAK monitor inlet port.

7. Insert the sample tube back into the port and screw it in using the sample tube removal tool.

8. Replace the inlet nozzle and O-ring.

9. Perform a zero check and re-zero if necessary.

10. Turn the DUSTTRAK monitor off and turn it on again while pressing and holding the CALIBRATE key. This action resets the internal circuit that keeps track of the total aerosol quantity that has gone through the instrument. The inlet port cleaning procedure is now completed.

Replacing the Internal Filters The internal filters should be replaced based on the schedule in Table 41 or when the SERVICE 5 is displayed during power-up. This service reminder will appear each time at power-up, until you reset this message. To reset the SERVICE 5 reminder, do the following:

1. Turn the instrument off.

2. Press and hold the CALIBRATE key while turning on the instrument.

3. The service message is now reset. If you change the filters before the SERVICE 5 message appears, you should reset this reminder by using the same technique. The operation of the built-in total mass tracking circuit is dependent upon the instrument calibration and the instrument flow rate. The assumed flow rate is 1.7 L/min. To replace the internal filters, follow the procedure below. Refer to Figure 4-3.

1. Move to a relatively clean environment (aerosol concentration less than 0.1 mg/m3).

2. Turn the DUSTTRAK Aerosol Monitor off.

Chapter 4 42

Figure 43: Internal Filter Replacement

3. Turn the aerosol monitor over on its keypad so the filter wells are facing up.

4. Use the small flat-blade screwdriver to unscrew the retaining screws at the center of each filter well. The screws are captive and will stay in the caps.

5. Grip the screw heads between your thumb and forefinger. Lift to pull the filter well caps off. There is an O-ring under each cap that may lift out with the cap.

6. Pull out the internal filter elements and discard them.

7. Clean the inside of the filter wells if necessary with a mild solvent like isopropanol and a cotton swab. Do not use compressed air.

8. Replace the internal filter elements with TSI part no. 800666.

Note: Only the recommended high efficiency particulate air (HEPA) filters should be used. The DUSTTRAK monitor should never be run without filters in place. Doing so will contaminate the optics and probably require you to send the unit back to the factory for cleaning.

9. Replace the O-rings and caps.

10. Use the small screwdriver to tighten the hold-down screws until finger-tight. Do not over-tighten.

Maintenance 43

11. Zero the mass tracking circuit to turn the service message off. This is done by pressing and holding the CALIBRATE key during power-up. The procedure is now completed.

Setting the Flow Rate The sample flow rate through the DUSTTRAK monitor is set at the factory at 1.7 L/min. The flow rate can be easily adjusted if necessary by following the procedure below. You need an instrument that precisely measures flow rate for use as a reference such as the flowmeter supplied with the DUSTTRAK monitor.

Note: The mass concentration readings are not affected by flow rate changes because the volume of sampled air seen by the DUSTTRAK detector is fixed. Flow rate is critical when using the cyclone or other aerosol separation devices.

1. Clean the inlet port as described in this chapter. If necessary, replace the internal filters as described in this chapter.

2. Connect the flowmeter to the DUSTTRAK monitor sample port using the tubing provided.

3. With the DUSTTRAK monitor running, use the supplied screwdriver to turn the flow adjustment screw located on the back of the DUSTTRAK monitor (see Figure 44). Observe the reading on the flowmeter (reading is taken at the center of the ball) and adjust the flow until the desired reading is obtained. The factory setting is 1.7 L/min.

4. Disconnect the flowmeter. The procedure is now completed.

Figure 44: Adjusting the Flow Rate

Chapter 4 44

Cleaning the Cyclone The 10-mm Nylon Dorr-Oliver Cyclone should be cleaned prior to each use. In most cases, simply cleaning the grit pot will be all that is needed. Inspect the inside of the cyclone body regularly and clean it if necessary.

1. Detach the cyclone from the DUSTTRAK monitor.

2. Unscrew the grit pot from the bottom of the cyclone and pull the top off the cyclone by pulling on the plastic tubing.

3. Hold the open end of the grit pot down and tap it on a hard surface to dislodge particles. Repeat with the cyclone body.

Note: If dirt is visible inside either the grit pot or the cyclone body, it may be necessary to blow compressed air into the cyclone parts and/or to clean them with soap and water. A mild solvent like isopropanol may also be used. Make certain that the cyclone is perfectly dry before using it.

4. Re-assemble the cyclone. Refer to Figure 45 below. The cyclone cleaning procedure is now completed.

Figure 45: Exploded View of 10 mm Nylon Dorr-Oliver Cyclone

Storage Precautions When storing the DUSTTRAK monitor for more than 30 days, you should remove the batteries. This prevents damage due to battery leakage. This instrument must be stored in a location where the temperature remains between 20 and 60C (4 and 140F).

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Chapter 5 Troubleshooting The table below lists the symptoms, possible causes, and recommended solutions for common problems encountered with the DUSTTRAK monitor. Symptom Possible Cause Corrective Action Erratic zero reading.

Leak. Dirty inlet port and/or sample tube. Sample nozzle missing. Internal filter(s) not installed properly (leaking).

Check connections for leaks. Replace zero filter. Tighten inlet cap. Clean inlet port. Clean or replace tubing. Remove inlet port cap and check sample nozzle. Replace if missing. Inspect internal filter wells to make certain the filters and o-rings are seated properly. Replace internal filters if necessary.

No display. Unit not switched on. Low or dead batteries. Batteries installed backwards. Dirty battery contacts.

Switch unit on. Replace the batteries or plug in the AC adapter. Observe polarity indication on battery holder diagram. Clean the battery contacts.

No keypad response.

Display/Lockout switch in lockout position.

Slide lockout switch to normal position (to the right).

Incorrect function displayed.

Two keys have been pressed at the same time.

Press only one key at a time.

Chapter 5 46

Symptom Possible Cause Corrective Action Battery symbol is displayed. (constant or blinking)

Low battery charge. Incorrect AC adapter. Low AC line Voltage Dirty battery contacts.

Replace batteries or use AC adapter. Replace with the correct AC adapter. Correct the AC line voltage or use batteries. Clean the battery contacts.

Analog output does not work

Cable/connector not correctly installed. Output wired with reverse polarity.

Make sure cable connector is fully seated. Make sure analog out (+) and analog ground (-) are wired correctly to data-logger.

Analog output is not in proportion to display

Analog output range in DUSTTRAK monitor may be set incorrectly. Data logger scaling factor may be set incorrectly.

Program analog output to desired range: 0 0.100 mg/m3 0 1.00 mg/m3 0 10.0 mg/m3 0 - 100 mg/m3 Scaling factor must be consistent with DUSTTRAK monitor.

Alarm output does not work. Alarm does not turn on correctly.

Alarm function not turned on. Alarm setting incorrect. Cable/connector not correctly installed. Alarm output wired with reverse polarity.

Alarm function is off by default. It must be programmed on (using TRAKPRO software). Program alarm setting using TRAKPRO software. Make sure cable connector is fully seated. Alarm wires are polarized. Voltage input must be wired to alarm input (+).

Maintenance 47

Symptom Possible Cause Corrective Action Display reads MEMORY 0%.

Memory is full. Download memory to a PC if desired, then clear memory.

SERVICE and 1 displayed.

Memory has been cleared due to temporary loss of power from internal backup battery.

Factory service required if condition persists. Press any key to bypass.

SERVICE and 2 displayed.

Calibration memory error. Internal calibration data corrupted.

Factory service required.

SERVICE and 3 displayed.

Backup battery low. Factory service required. Press any key to bypass.

SERVICE and 4 displayed.

The sample inlet nozzle is due for cleaning.

Clean the nozzle and sample inlet port. Press any key to bypass.

SERVICE and 5 displayed.

Internal filters are due for replacement.

Replace internal filters and reset service reminder. See Replacing the Internal Filters for more information.

SERVICE and 6 displayed.

Flow obstruction on previous power up. Internal pump failing, indicated by inability to adjust flow rate to full range.

Remove obstruction if still present. Press any key to bypass. If Service 6, recurs on each power up even after bypassing, factory service may be required.

Chapter 5 48

Symptom Possible Cause Corrective Action SERVICE and 7 displayed.

High humidity or laser failure.

Typically occurs if the unit is turned ON either after sampling under high humidity conditions or when instruments are stored at a different temperature than that of the sampling area. Bypass this error by pressing Calibrate key. Zero the DUSTTRAK by following the instructions given in Chapter 4, Maintenance, under section Zero Checking/Re-Zeroing. If the unit cannot be zeroed, let the DUSTTRAK equilibrate to ambient conditions and try zeroing the DUSTTRAK again. If the Service 7 error still persists, it might be due to laser failure and the unit needs to be returned to TSI.

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Appendix A Specifications Specifications are subject to change without notice. Sensitivity: Sensor type: ..................... 90 light scattering, laser diode Range: ............................. 0.001100 mg/m3 (calibrated to respirable

fraction of standard ISO 12103-1, A1 test dust)

Resolution: ...................... 0.1 % of reading or 0.001 mg/m3, whichever is greater

Zero stability: .................... 0.001 mg/m3 over 24 hours using 10-second time-constant

Particle size range: .......... 0.1approximate 10 m (Upper limit is dependent on flow rate)

Flow rate range: ............... 1.42.4 L/min. Temperature coefficient: .. +0.001 mg/m3 per C (for variations from

temperature at which DUSTTRAK monitor was zeroed)

Instrument Temperature Range: Operating range: ............. 0 C to 50 C (32 F to 120 F) Storage range: ................ -20 C to 60 C (-4 F to 140 F) Time Constant: Range: .............................. Adjustable from 1 to 60 seconds Data Logging: Data points: ...................... >31,000 (21 days logging every minute) Logging interval: ............... Adjustable from 1 second to 1 hour Analog Output (selected instruments only): Selectable ranges: ........... 0 0.100 mg/m3

0 1.0 mg/m3 0 10.0 mg/m3 0 100 mg/m3

Voltage output .................. 0 5 VDC Output impedance ............ 0.01 ohms Maximum current ............. 15 mA

Appendix A 50

Alarm Output (selected instruments only): Range ............................... 0.002 to 100 mg/m3

Maximum voltage input .... 15 VDC Maximum current ............. 1 amp Physical: External dimensions: ........ 221 mm x 150 mm x 87 mm (8.7 in x

5.9 in x 3.4 in) Weight (with batteries): ... 1.5 kg (3.3 lb.) Display: ............................. 4 digit LCD, 15 mm (0.6 in) digit height Factory Maintenance: Factory clean/calibrate: .... Annually User Maintenance: User calibration: ............... As needed Clean nozzle: ................... After every 350 hours at 1 mg/m3

(e.g., 350 hours at 1 mg/m3, 35 hours at 10 mg/m3 or 3.5 hours at 100 mg/m3)

Change internal filters: ..... After every 700 hours at 1 mg/m3 (e.g., 700 hours at 1 mg/m3, 70 hours at 10 mg/m3 or 7 hours at 100 mg/m3)

Serial Interface: Type: ................................ RS-232 BAUD rate: ....................... 1200 Data Bits: .......................... 8 Stop Bits: .......................... 1 Data Format: .................... ASCII Power Requirements: External Adapter: ............. 6 VDC, 300 ma or Batteries: .......................... 4 C-size Alkaline Battery run-time: ............... 16 hours (typical) EMI/RF Immunity: 1. Complies with Emissions Directive Standard: EN50081-1:1992 2. Complies with Immunity Directive Standard: EN50082-1:1992